Page 2385 of 3051
SEM066G
13. Install thermostat housing with water pipe.
SEM030G
14. Install intake manifold supports.
BEM006
SEM051G
15. Remove old liquid gasket from mating surfaces of rocker cover
and cylinder head.
16. Apply a continuous bead of liquid gasket to rocker cover gas-
ket and cylinder head as shown in the illustrations.
+Use Genuine RTV silicone sealant Part No. 999MP-A7007
or equivalent.
CYLINDER HEADSR
Installation (Cont'd)
EM-128
Page 2386 of 3051
SEM052G
17. Install rocker cover and oil separator.
+Be sure to install washers between bolts and rocker cover.
+Tightening procedure
STEP 1: Tighten bolts1-10-11-13-8inthat order.
STEP 2: Tighten bolts1-13inthat order.
:8-10N´m(0.8 - 1.0 kg-m, 69 - 87 in-lb)
18. Install the following parts:
+Spark plugs and leads
+Radiator
Refit hoses and refill with coolant.
Refer to LC-38, ªChanging Engine Coolantº.
+Front RH wheel
+Engine under covers
19. Connect the following:
+Vacuum hoses
+Fuel hoses
+Wire harnesses and connectors
+Air duct to intake manifold
+Front exhaust tube
CYLINDER HEADSR
Installation (Cont'd)
EM-129
Page 2387 of 3051

Removal and InstallationNLEM0137
NEM354
1. Stopper
2. Bracket
3. Front insulator assembly4. Center member
5. Pad
6. Right insulator assembly7. Bracket
8. Rear insulator assembly
9. Left insulator assembly
WARNING:
+Position vehicle on a flat and solid surface.
+Place chocks at front and back of rear wheels.
+Do not remove engine until exhaust system has com-
pletely cooled off, otherwise you may burn yourself and/or
fire may break out in fuel line.
+Before disconnecting fuel hose, release pressure. Refer to
EC-578, ªFuel Pressure Releaseº.
+Before removing front axle from transaxle, place safety
stands under designated front supporting points. Refer to
GI-43, ªGarage Jack and Safety Standº.
+Be sure to lift engine and transaxle in a safe manner.
+For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.
CAUTION:
+When lifting engine, be sure to clear surrounding parts.
Use special care near accelerator wire casing, brake lines
and brake master cylinder.
+In lifting the engine, always use engine slingers in a safe
manner.
+In removing drive shaft, be careful not to damage grease
seal of transaxle.
+Before separating engine and transaxle, remove the
ENGINE ASSEMBLYSR
Removal and Installation
EM-130
Page 2388 of 3051

crankshaft position sensor (OBD) from the assembly.
+Always be extra careful not to damage edge of crankshaft
position sensor (OBD) or ring gear teeth.
SEM174D
REMOVALNLEM0137S011. Remove engine under covers and engine side cover.
2. Drain coolant from both cylinder block and radiator. Refer to
LC-38, ªChanging Engine Coolantº.
3. Drain engine oil.
4. Remove air cleaner assembly and duct.
5. Remove the battery and battery tray.
6. Disconnect the following:
+Vacuum hoses
+Heater hoses
+A/T cooler hoses
+Power steering hoses
+Fuel lines
+Wires
+Harnesses and connectors
+Throttle cable
7. Remove the cooling fans, radiator and reservoir tank.
8. Remove front LH and RH wheels and drive shafts. Refer to
AX-10, ªDrive Shaftº.
9. Remove front exhaust pipe.
10. Remove starter and intake manifold support.
11. Remove the drive belts.
12. Remove power steering oil pump and A/C compressor.
13. Set a suitable transmission jack under transaxle. Lift engine
with engine slinger.
SEM092D
14. Remove center member.
15. Remove generator and adjusting bracket.
ENGINE ASSEMBLYSR
Removal and Installation (Cont'd)
EM-131
Page 2389 of 3051
SEM040G
16. Remove engine mounting bolts from both sides, then slowly
lower transmission jack.
SEM195F
17. Remove engine with transaxle as shown.
INSTALLATIONNLEM0137S021. Install in the reverse order of removal.
ENGINE ASSEMBLYSR
Removal and Installation (Cont'd)
EM-132
Page 2390 of 3051
ComponentsNLEM0138
NEM350
1. Rear oil seal retainer
2. Cylinder block
3. Water pump
4. Power steering oil pump adjusting
bar
5. Front cover with oil pump
6. Oil strainer
7. Thrust bearing
8. Crankshaft9. Connecting rod bushing
10. Piston rings
11. Piston
12. Piston pin
13. Connecting rod
14. Connecting rod bearing
15. Aluminum oil pan
16. Rear cover plate
17. Oil pan drain plug18. Steel oil pan
19. Baffle plate
20. Main bearing cap
21. Pilot converter
22. Drive plate
23. Reinforcement plate
24. Rear plate
25. Main bearing
CYLINDER BLOCKSR
Components
EM-133
Page 2391 of 3051

Removal and InstallationNLEM0139CAUTION:
+When installing sliding parts (bearings, pistons, etc.),
lubricate contacting surfaces with new engine oil.
+Place removed parts, such as bearings and bearing caps
in their proper order and direction.
+When installing connecting rod nuts and main bearing cap
bolts, apply new engine oil to threads and seating sur-
faces.
+Do not allow any magnetic materials to contact the ring
gear teeth of drive plate.
SEM141FA
DisassemblyNLEM0140PISTON AND CRANKSHAFTNLEM0140S011. Place engine on engine stand (ST0501S000).
2. Remove cylinder head and timing chain.
Refer to EM-97, EM-109.
3. Remove oil pan.
Refer to EM-91.
SEM877B
4. Remove pistons with connecting rods.
+To disassemble piston and connecting rod, first remove snap
rings. Heat piston to 60 to 70ÉC (140 to 158ÉF) then use pis-
ton pin press to remove pin.
+When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.
+When replacing piston rings, if there is no punch mark,
install with either side up.
5. Remove rear oil seal retainer.
SEM068G
6. Remove main bearing cap and crankshaft as shown.
+Bolts should be loosened in two or three steps.
AEM023
InspectionNLEM0141PISTON AND PISTON PIN CLEARANCENLEM0141S011. Measure inner diameter of piston pin hole ªdpº.
Standard diameter ªdpº:
21.993 - 22.005 mm (0.8659 - 0.8663 in)
CYLINDER BLOCKSR
Removal and Installation
EM-134
Page 2392 of 3051

AEM024
2. Measure outer diameter of piston pin ªDpº.
Standard diameter ªDpº:
21.989 - 22.001 mm (0.8657 - 0.8622 in)
3. Calculate interference fit of piston pin to piston.
dp - Dp: 0.002 - 0.006 mm (0.0001 - 0.0002 in)
If it exceeds the above value, replace piston assembly with pin.
SEM024AA
PISTON RING SIDE CLEARANCENLEM0141S02Side clearance:
Top ring
0.040 - 0.080 mm (0.0016 - 0.0031 in)
2nd ring
0.030 - 0.070 mm (0.0012 - 0.0028 in)
Max. limit of side clearance:
0.1 mm (0.004 in)
If out of specification, replace piston ring. If clearance exceeds
maximum limit with new ring, replace piston.
SEM822B
PISTON RING END GAPNLEM0141S03End gap:
Top ring 0.20 - 0.39 mm (0.0079 - 0.0154 in)
2nd ring 0.35 - 0.59 mm (0.0138 - 0.0232 in)
Oil ring 0.20 - 0.69 mm (0.0079 - 0.0272 in)
Max. limit of ring gap:
1.00 mm (0.0209 in)
If out of specification, replace piston ring. If gap exceeds maximum
limit with a new ring, rebore cylinder and use oversized piston and
piston rings. Refer to SDS, EM-153.
+When replacing the piston, check cylinder block surface for
scratches or seizure. If scratches or seizure are found, hone
or replace the cylinder block.
CYLINDER BLOCKSR
Inspection (Cont'd)
EM-135